Fuel cell electrolyte reservoir layer and method for making

ABSTRACT

A porous graphite reservoir layer for retaining electrolyte within a fuel cell is improved by coating the pore surfaces of the reservoir layer with wettable, particulate amorphous carbon. Preferably the amorphous carbon particles are colloidal and have a mean pore size considerably smaller than the pore size of the body which they coat. This coated reservoir retains its hydrophilic properties for an extended period of time.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to fuel cells, and more particularly toelectrolyte volume control within a fuel cell.

2. Description of the Prior Art

Electrolyte reservoir layers or plates disposed in fuel cells are wellknown for accommodating volume changes in the electrolyte during fuelcell operation. The following commonly owned U.S. Patents relate to fuelcell reservoir layers: U.S. Pat. Nos. 3,779,811; 3,905,832; 4,035,551;4,038,463; and 4,064,322. Obviously, these reservoir layers must be madefrom either hydrophilic material or from material which is treated so asto be hydrophilic in order that they readily retain electrolyte withintheir pores.

A material commonly suggested for use as a reservoir layer in aphosphoric acid electrolyte fuel cell is carbon fibers bonded togetherwith a resin, such as a phenolic resin, and heated to convert the resinand carbon fibers to graphite. Alternatively, carbon or graphite fibersmay be bonded together with pyrolytic graphite by placing a mat offibers in a decomposable hydrocarbon (e.g., methane) atmosphere underconditions which cause the hydrocarbon to break down into carbon andhydrogen. The carbon (now pyrolytic graphite) deposits on the fibers.Materials of the two foregoing types are available commercially and arereferred to in the art as carbon papers.

Several problems have been experienced when using these materials aselectrolyte reservoirs. For example, although these materials areinitially hydrophilic, when exposed to air and moisture the materialbecomes hydrophobic over a period of several months. This is the resultof a carbon/oxygen specie forming a layer on the exposed surfaces of thematerial. Thus, these materials have a poor shelf life or may requirespecial storage prior to use.

Even if these reservoir layers are placed into a fuel cell immediatelyupon fabrication, when disposed on the anode side of the cell theexposure to hydrogen and water vapor at cell operating temperatures alsoresults in the slow formation of a hydrophobic compound on the exposedsurfaces of the material. This reduces the effectiveness of thereservoir layer over a period of time and also makes it difficult toreplenish the cell with electrolyte if such becomes necessary.

SUMMARY OF THE INVENTION

An object of the present invention is a hydrophilic reservoir layer fora fuel cell which does not lose its hydrophilic property with time undernormal operating conditions.

According to the present invention, an electrolyte reservoir comprises aporous, hydrophilic graphitic body having a coating of particulate,wettable, amorphous carbon on its pore surfaces.

As used herein, "pore surfaces" means the surfaces which form the poresof the graphite body; and "wettable"means wettable by the electrolyteused in the fuel cells. Wettable is sometimes used interchangeably with"hydrophilic."

In the usual case the porous graphite body comprises a sheet ofgraphitized carbon fibers bonded together with a pyrolytic graphite orwith a resin which has been converted to graphite. In the alternativethe porous graphite sheet material may be made by molding graphitepowder and a resin, such as phenolic resin, and heating the molded bodyto graphitize the resin. In either case this material is at least 50%porous and preferably is at least 75% porous.

The amorphous carbon which is selected to form the coating on thesurfaces of the graphite body must have several properties. One requiredproperty is that the carbon be wettable by the electrolyte.Hydrophilicity of the carbon may be defined in terms of its oxygencontent. We suggest that the oxygen content of the amorphous carbon beat least one percent by weight. Additionally, the particle size of theamorphous carbon should be at least one and preferably two or moreorders of magnitude smaller than the pore size of the uncoated graphitebody in order that the amorphous carbon particles can readily enter thepores of the graphite body and form a thin, uniform coating on the poresurfaces without substantially reducing the porosity of the body. Thisgenerally means the amorphous carbon particles will need to be colloidalin size since the uncoated graphite body will typically have a mean poresize of somewhere between 10 and 100 microns. It is believed a coatinghaving a thickness of only one or two particles is sufficient and willbe effective.

In addition to the foregoing properties, the amorphous carbon selectedfor use in the present invention should have a moderate to high surfacearea such that the pores of the particles in the coating are smallenough to hold electrolyte with sufficient tenacity to ensure thatsubstantially all the pore surfaces of the reservoir layer are alwayswet. Preferably the particles will have a mean pore size of less thanabout 0.1 micron. This will probably be at least two orders of magnitudeless than the mean pore size of the uncoated graphite body. It is feltthat the coating's ability to retain electrolyte and thus keep the poresurfaces of the underlying graphite material continuously wet isresponsible for preventing the reservoir layer from becominghydrophobic. Tests to date have shown that the present invention canextend the useful life of a reservoir layer by at least a factor of ten.

A preferred method for applying the amorphous carbon coating to thegraphite body is to form a stable liquid dispersion of the amorphouscarbon and to impregnate the graphite body with this dispersion so as tosaturate the void volume. The liquids are thereafter removed by heating.Since no binder is used to attach the coating to the surfaces of thegraphite body, Van der Waals forces are relied upon for this purpose.Van der Waals forces are inversely proportional to particle size. Thus,a further reason exists for utilizing small and preferably colloidalsize amorphous carbon particles.

The foregoing and other objects, features, and advantages of the presentinvention will become more apparent in the light of the followingdetailed description of preferred embodiments thereof as illustrated inthe accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING

The sole FIGURE is a transverse sectional view showing anelectrochemical cell which includes a reservoir layer.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A "carbon paper" mat ideally suited as the underlying graphite body ofthe reservoir layer was made by mixing Union Carbide's VMA grade choppedcarbon fibers (nominal diameter 10μ) with a phenolic resin, forming thecoated fibers into a mat or sheet, and heating the mat to at least 2100°C. to convert the carbon fibers and the resin to 100% graphite. The matwas 75% porous, had a thickness of about 0.075 inch, a pore size rangeof from 20μ to 60μ and a mean pore size of 40μ.

A stable aqueous colloidal dispersion of amorphous carbon was formed byultrasonically blending 1624 grams of Vulcan® XC-72 carbon into amixture consisting of 98,400 milliliters H₂ O and 492 millilitersTriton® X-100 surfactant. Vulcan XC-72 carbon is a highly porous,wettable amorphous carbon powder manufactured by Cabot Co., Billerica,MA having a surface area of about 270 n² /g, a particle size range offrom 0.1 to 1.0 micron, and an oxygen content of greater than one andusually less than two weight percent. Triton X-100 is a non-ionicsurfactant manufactured by Rohm and Haas of Philadelphia. It dispersesthe carbon and also lowers the surface tension of the dispersion tofacilitate impregnation and wetting of the graphite mat.

The graphite mat was then impregnated with the foregoing aqueousdispersion in a manner which ensured that the entire void volume of themat was saturated. We impregnated the mat by passing it once betweenrollers having a sponge-like surface which is constantly soaked with theaqueous dispersion by having the lower portion of the roller sitting ina bath of the dispersion. The method for impregnating the mat is notcritical to the present invention. For example, the mat could beimpregnated by dipping it in a bath of the aqueous dispersion, bydripping the dispersion onto the mat, or by spraying the mat with thedispersion.

The liquids were then removed from the impregnated mat. In the presentexample the water was evaporated and the Triton X-100 surfactant wasburned off by heating in air at 650° F. for five minutes. In accordancewith the present invention the liquids could have been removed by anysuitable combination of heating and/or leaching, as required.

The thickness of the resulting amorphous carbon coating is preferablythe minimum thickness necessary to impart the required wettability tothe graphite mat pore surfaces. The maximum acceptable thickness will bedetermined by the minimum acceptable porosity of the coated mat,realizing that the porosity is reduced as the thickness of the coatingincreases. The coating thickness will be partially determined by thesolids content of the dispersion. In the foregoing example the solidscontent of the dispersion was 0.16 weight percent; and the single passimpregnation procedure described above resulted in an effective, uniformcoating having a thickness of only about one monolayer of particles.Dispersion with solids contents of less than about 0.10 weight percentproved to be unacceptable, at least with our coating procedure.

The above described amorphous carbon coated graphite mat has been rununder anode operating conditions in a fuel cell using phosphoric acidelectrolyte for 30,000 hours without becoming hydrophobic. This compareswith prior art mats which, under similar operating conditions, wouldbecome hydrophobic in just 2000 to 3000 hours.

The sole FIGURE shows the foregoing reservoir layer in an exemplary fuelcell configuration. The fuel cell is shown and designated by the numeral10. The fuel cell 10 includes an electrolyte retaining matrix 12, ananode electrode 14, a cathode electrode 16, and gas separators 18, 20.The cell uses phosphoric acid as the electrolyte.

In this embodiment the anode electrode 14 includes a catalyst layer 22bonded to a reservoir layer 24 made in accordance with the procedureoutlined above; thus, the reservoir layer in this embodiment is also anelectrode substrate since it supports the catalyst layer. The gasseparator 18 includes ribs 26 and an edge portion 28. Hydrogen or othersuitable fuel is introduced into the fuel spaces 29 between thereservoir layer and the gas separator. In a stack of fuel cells theseparator 18 would have oxidant on the other side thereof for feedingthe cathode electrode of an adjacent cell. The catalyst layer 22 iscomprised of catalyst particles bonded together with a hydrophobicmaterial such as polytetrafluoroethylene. A preferred catalyst isplatinum supported on carbon particles.

Liquid transfer within the cell occurs through the action of capillaryforces. The smaller the pore, the larger the capillary force and thegreater the liquid retention capability. Liquid transfer between thematrix 12 and the reservoir layer 24 occurs directly through the poresof the catalyst layer 22 which is partially hydrophilic. In any event,the catalyst layer may be provided with holes to aid in this liquidtransfer if desired or if it is felt to be necessary.

In this exemplary embodiment the cathode electrode 16 also comprises areservoir layer 30 having a catalyst layer 32 bonded thereto. It shouldbe noted, however, that in many applications a reservoir layer on onlyone side of the cell will be necessary or desirable. The separator 20also includes ribs 34 and an edge portion 36. The ribs 34 of the cathodeare parallel to the plane of the paper and form oxidant spaces 38between the separator 20 and the reservoir layer 30.

In this embodiment the reservoir layers 24, 30 include peripheralsealing portions 40, 42, respectively. These sealing portions aresandwiched between the edge portion 44 of the matrix 12 and the edgeportions 28, 36 of the gas separators 18, 20, respectively. The sealingportions 40, 42 are impregnated, such as with the material of which thematrix 12 is made in order that the entire void volumes of theseportions always remain essentially completely filled with electrolyte aslong as the matrix 12 is filled with electrolyte. Liquid seals arethereby formed at the surfaces 46, 48, 50, and 52 in the mannerdescribed in U.S. Pat. No. 3,867,206 of common assignee with the presentinvention. The seals prevent the escape of reactant gas from within thecell. They form no part of the present invention.

The above described type of fuel cell construction, which is similar tothat shown in aforementioned U.S. Pat. No. 4,035,951, is exemplary ofthe type in which a reservoir layer of the present invention may beemployed. It should be apparent, however, that the reservoir layer ofthe present invention may be utilized in virtually any fuel cellconfiguration, such as those described in the other commonly owned U.S.patents mentioned in the Background of the Invention. In particular, theelectrode may have a conventional substrate (to which the catalyst layeris bonded) which is not intended to provide significant electrolytestorage for volume control. In those cells a separate reservoir layer isusually disposed behind the conventional electrode substrate but inliquid communication with the electrolyte retaining matrix. This type ofconstruction is shown in aforementioned U.S. Pat. Nos. 3,779,811 and3,905,832. U.S. Pat. Nos. 4,038,463 and 4,064,322 describe fuel cellconfigurations wherein the reservoir layer is selectively wetproofed toprovide better reactant gas flow from the reactant gas space to thecatalyst layer. It is apparent that reservoir layers according to thepresent invention may also be selectively wetproofed.

It is also apparent that the reservoir/substrate layers 24, 30 may beconfigured in accordance with the teachings of U.S. Pat. Nos. 4,115,627whereby they, instead of the separators 18, 20, include the ribs whichhelp define the reactant gas spaces.

Although the invention has been shown and described with respect to apreferred embodiment thereof, it should be understood by those skilledin the art that other various changes and omissions in the form anddetail thereof may be made therein without departing from the spirit andthe scope of the invention.

Having thus described a typical embodiment of my invention, that which Iclaim as new and desire to secure by Letters Patent of the United Statesis:
 1. A reservoir comprising a porous, hydrophilic graphite body havinga coating of particulate, wettable, amorphous carbon on its poresurfaces.
 2. The reservoir according to claim 1 wherein said amorphouscarbon has an oxygen content of at least 1.0 weight percent.
 3. Thereservoir according to claim 1 wherein said particulate carbon iscolloidal in particle size.
 4. The reservoir according to claim 1wherein the mean pore size of said particulate carbon is at least twoorders of magnitude less than the mean pore size of the uncoatedgraphite body.
 5. The reservoir according to claim 1 wherein the meanpore size of said particulate carbon is less than 0.1 micron.
 6. Thereservoir according to claim 3 wherein said coating is so thin theporosity of the coated body is virtually unchanged from that of theuncoated body.
 7. The reservoir according to claim 1 wherein saidgraphite body comprises graphitized carbon fibers.
 8. An electrolytereservoir comprising a porous, hydrophilic graphite body having acoating of colloidal size amorphous carbon articles on its poresurfaces, said particles having an oxygen content of at least 1.0 weightpercent and a mean pore size of less than 0.1 micron, said coatedreservoir having a porosity of at least 50%.
 9. The reservoir accordingto claim 8 having a porosity of at least 75%, wherein the mean pore sizeof said graphite body is between 10 and 100μ.
 10. The reservoiraccording to claim 9 wherein said graphite body comprises graphitizedcarbon fibers bonded together with a resin which has been converted tographite.
 11. The reservoir according to claim 9 wherein said graphitebody comprises graphitized carbon fibers bonded together with pyrolyticgraphite.
 12. In an improved fuel cell utilizing a phosphoric acidelectrolyte and a porous reservoir layer for controlling electrolytevolume within the cell, the reservoir layer comprising graphitizedcarbon fibers bonded together, the improvement comprising:a coating ofparticulate, wettable, amorphous carbon on the pore surfaces of saidreservoir layer.
 13. The improved fuel cell according to claim 12wherein said reservoir layer includes a catalyst layer adjacent and incontinuous contact therewith.
 14. The improved fuel cell according toclaim 12 wherein said amorphous carbon particles are colloidal and havea mean pore size at least two orders of magnitude less than the meanpore size of the uncoated reservoir layer.
 15. The improved fuel cellaccording to claim 14 wherein said coated reservoir layer has a porosityof at least 75%.